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Old 04-16-2014, 06:15 PM
ncsucarjock88 ncsucarjock88 is offline
TT Regular
Join Date: Feb 2014
Boat: 87 PS190, powerslot
Location: Southeast
Posts: 64
'87 PS190 mild refreshing


Picked this boat up about a month ago... Looked good, ran well, and thought I would do a few minor things before ski season...

Then MCOCD hit...

Started with the simple stuff. Vacuum. Get rid of all the dog hair. Clean the interior vinyl (all original except for the observers seat bottom), and protect it.

Then onto the ski platform, which had been varnished at some point, and was flaking and generally looked like crap. A heat gun, scrapers, and a few hours later and it was looking much better. Followed that up with some 120 grit sanding, and got it nice. Found a seam was just starting to delaminate on the front, so I glued that back together before it got bad. Then I used a combo of boiled linseed oil (75%) and 25% mineral spirits. It got three coats of that before it didn't want to absorb anymore. I'm really pleased with how it looks.

Notice the gel-coat in this pic, in particular the grey part on the stern.

But... it made me realize that my transom had some oxidation on the gelcoat, and the whole boat really could use a light compounding, and it definitely needed wax. It was lacking much reflection, and there was obviously no wax on it... So I got to work. Sadly, I didn't take any good pics of this. This wasn't anything dramatic or crazy... and we've all seen the oxidation threads.

Wound up buying a cheap rotary from Harbor Freight (those things are surprisingly good for the price - so are their wool bonnets). My Porter Cable 7424 Random Orbit just didn't have the umph to cut through the gelcoat. A wool bonnet with Meguires 105 compound was put to work. Didn't take long to do the entire boat with this combo. The hardest part was the bow - which took about 4 passed of breaking down the 105 completely before I got down to a decent shine. 105 is liquid sandpaper, and doesn't leave a great finish. So I brought out the PC 7424, threw a hard Sonus Pad on it, and went at it with the Meguires 205. Two passes with the 205, and the trace from the 105 was gone, leaving good looking gelcoat. Far from perfect, but good enough for me, without going to the level of removing all the decals. I was just light over the decals and pinstriping and polished right over all of that. Then I picked up some new wax - and dear lord - I love this stuff... It's Meguires Ultimate Liquid Wax. Its actually a polymer, but it goes on *sooo* easy (careful, it's invisible, so you have to be very diligent about making sure you don't miss a spot...). Three coats of that went on the boat, and the reflection is as good as it's gonna get without a wetsand with 2000 and then polish back up from there. And she's protected.

Here are a couple pics after I pulled her out of the shop. And do pardon the...umm... Sanford and Son tow vehicle. The Jeep (which is quite obviously an off-road toy - has lived a *very* hard life, and yes - that's oil burning - and yes - it does that all the time now - and yes, it's a gas engine - sorta - It's ingested entirely too much mud into the cylinders... amazing it runs...). The Dodge Ram in the background is the tow vehicle, but I can't maneuver the boat with the Dodge and get it in and out of the shop/garage (two different places on the same property). I need the short wheelbase of the Jeep for maneuvering. Glad she's still around...she's still got usefulness. And yes, I not-so-secretly love my Jeep with it's smokestack.

Change the oil and transmission fluid. Take it out for a test run. Found that my packing bearing was a miniature sprinkler... Ordered new packing material. Also found one leaking manifold, and a leaking water pump.

So I ordered new manifolds (ebay, thanks - $390 total, including gaskets, hardware, and shipping... they arrived in a week.

This is why I need the Jeep. I work on a lot of stuff up at the shop - where all the tools are, and the boat stays down in the garage at the house... but... This is the clearance getting into and out of the garage...and it's at an odd-angle, and uphill. Beautiful.

Meanwhile... I took the boat out and did something crazy! I anchored it overnight in the local lake (my dad is a park ranger, and it was anchored where he could keep an eye on it). I left him the keys... and headed back to the shop with the trailer...

The wiring on the trailer was original, and had enough splice connectors none of it should have worked. Add to that the fact that the pigtail wasn't long enough for slack on my truck, and the ground wire was just about to break, the left turn had broken once and had been patched at least once at the pigtail... well... you get the idea...

The trailer did have nice new LED lights, so I ordered up 100' of trailer wire from Amazon and a new connector that fits my truck (which has an oddball 6-pin). Gathering my heat shrink, liquid electrical tape, soldering iron, solder, acid flux (to clean the old wire on the lights) - I set about rewiring the sucker. Sorry, I don't have pics of this.

Ran all new wire to the rear - spitting off the main runs. Every connection was soldered, then covered in liquid electrical tape, then I added a "sealing layer" of electrical tape before sliding the heat shrink over the connection, and melted everything down. This way I had a little electrical tape coming out the ends of my heatshrink, and a very well insulated, soldered joint. Someone had previously added 4 grounds to the trailer - one by each fender, and one at the rear lights. I kept those connections on the trailer undisturbed because they functioned, and I suspect they are not stainless connections, and I didn't want to re-drill and re-do all that. The trailer will need a major overhaul next year - this is just temporary lighting so that I won't be that jerk on the road that I cuss who doesn't have trailer lights...

Started about 2pm, and finished about 10pm. Took awhile, but its worth the extra time to have reliable trailer lights. I ran dual grounds all the way from front to rear, as well as dual parking lamps. Hopefully there will be no more issues with the lights, period.

While the boat was in the water (did I mention I was nervous having her anchored out there...) I decided to upgrade the trailer carpet as well, it was thin in several spots, and the V-notch was down to bare wood on one side. Lowes didn't have any black carpet, so I had to settle on blue/grey, which I think looks really good actually.

I took the sander and rounded the edges of the boards (why are mine 2x4s?? Everyone else seems to talk about 2x6's??...hmmm) Anyhow... those rounded, I cut my carpet 4.5" wide, and stapled that to the inside rail of the 2x4, on the side of the 2x4. Then I cut a strip about 7.5" wide, and stapled that to the outside edge of the 2x4, wrapping around and trapping the first layer of carpet, and secured that all the way under the 2x4 on the inside. Take your time, pull, and it'll work just fine. Really didn't take that long to do this. A few hundred staples later, and I was done. As a final step... I finally pulled out my bottle of brand new wax that I love, and since it's liquid, I squeezed on two beads all the way down both bunks of the carpet, and rubbed that in. I'd been noticing it was taking a lot of power to get the bar connected on the trailer, and there are some minor marring marks on the hull. No more!.

While I was there, I compounded the trailer fenders, with 105 and 205, and then gave them two coats of wax as well.

Went back to the lack, fetched the (now very pollen covered) boat, and went for a ride with Dad... then put it back on the trailer - much, much, much easier to load.

Wiped her down, and put her back in the garage.
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Old 04-16-2014, 06:21 PM
Xjet2011 Xjet2011 is offline
TT Regular
Join Date: May 2012
Boat: 1986 mastercraft ford 351 240 hp and now a second boat 1990 Prostar Powerslot. Same Motor as the 86
Location: S florida Lake Okeeheelee area
Posts: 36
Awesome. Nice Job.
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Old 04-16-2014, 06:39 PM
ncsucarjock88 ncsucarjock88 is offline
TT Regular
Join Date: Feb 2014
Boat: 87 PS190, powerslot
Location: Southeast
Posts: 64
So this week the manifolds arrived, and I set about replacing those yesterday...

Old setup

I was worried about getting the bolts out... I had been soaking them for a week with PB Blaster, and had actually heat cycled the engine several times.

That little gear wrench drive is the bomb for so many things. Supports an amazing amount of torque applied, and is awesome for tight spaces.

While I had things apart (and really, don't judge the ugly engine bay. Engine really needs to be pulled, blasted, painted, bay detailed, and put back in). Just not happening before ski season....

I decided to pull all the plugs, check their condition, and the condition of the engine burn, and do a compression test.

Plugs look great. Very consistent color, the electrode is changing color right at the edge of the bend like it should. And the plugs are pretty new. So is the cap and rotor, and the wires appear to be relatively recent. All good things here.

Decided to run a compression test while I had all the plugs out, so that I had a baseline. Engine has 633 hours on it, and I was pleased with the compression test. I don't know the numbering convention yet on this Ford, so pardon my rather generic numbering. I need to learn the firing order and cylinder order on this engine.

And back to the manifolds...

I used a scotch brite on a die grinder to clean up the gasket surfaces.... most looked great...but..
I'm a little concerned about the pitting here... but... I used some High temp copper RTV along with the gasket included... and I put things back together... I think it'll all be good.

No pics of it, but I also gasket matched the new gasket to the ports. There was a fair bit of overhang and slack, and though I'm sure the exhuast would have eventually taken care of it, I just trimmed the gasket to fit appropriately with the ports on the manifold.

Manifold installed, and I torqued things down to 35 ft/lbs.

Notice the Copper RTV here - I have similar pitting on my risers...


Now it's time for a boat ride... but I still have a new water pump to install... and some hoses. The front hoses that go into the manifold, there is a 1" barb fitting there. I didn't realize that old fitting is plastic, and it doesn't want to come out of the old manifold. I plan on heading to the local hardware store tomorrow and grabbing a 1" brass or steel adapter for that, rather than plastic. I really want brass there... for looks, durability, and non-corrosiveness...

Pardon the dirty interior... and yes... I wore shoes in my boat... Dropping something cast iron is bad... and dropping it on a bare foot would really not be fun. So, pardon the crime ;-)
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Old 04-16-2014, 07:04 PM
thatsmrmastercraft's Avatar
thatsmrmastercraft thatsmrmastercraft is offline
MC Master Poster
Join Date: Sep 2008
Boat: 1977 Stars & Stripes
Location: St. Paul, MN
Posts: 13,911
You don't kid around when you start a thread. Great work all around.

Tandem Axle Trailer Special
Includes: 4 T07 wheels, 4 ST205/75R14 Kenda
Loadstar KR03 Radial tires, mount and balance
Free Delivery

LED lights, Spare Tire Carriers, Chrome & Powder Coated Lug Nuts

PM me or email tiresplease@gmail.com
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Old 04-16-2014, 09:22 PM
orbeamlb's Avatar
orbeamlb orbeamlb is offline
MC Fanatic
Join Date: Feb 2012
Boat: 1988 ProStar 200, 1991 Mercury 2.5L 200hp XRi Outboard
Location: Austin, Texas
Posts: 669
Nice work, boat looks great! Love those colors too.
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Old 04-17-2014, 08:27 AM
JohnE's Avatar
JohnE JohnE is offline
Join Date: Jan 2006
Boat: 1997 '190 LT-1/ 'slot
Location: Boston 'burbs
Posts: 8,256
Originally Posted by thatsmrmastercraft View Post
You don't kid around when you start a thread. Great work all around.
That's what I was thinking. Nice job.
'97 Prostar 190 - LT-1

Prior boats - 2009 X14, 2008 X14, 2005 197, 1988 Tristar 190, 1989 Prostar.
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Old 04-17-2014, 08:58 AM
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19_Skier 19_Skier is offline
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Join Date: Dec 2011
Boat: 2001 19Skier
Location: Ontario
Posts: 413
Originally Posted by thatsmrmastercraft View Post
You don't kid around when you start a thread. Great work all around.
agreed, the thread title is deceiving - well done, great looking boat.
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Old 04-17-2014, 09:36 AM
ncsucarjock88 ncsucarjock88 is offline
TT Regular
Join Date: Feb 2014
Boat: 87 PS190, powerslot
Location: Southeast
Posts: 64
Well...nothing major here... just little stuff that the PO didn't address or had let go... Still got a few things left...

Water pump replacement, fix the speedos (is there a good tutorial on this, I sure haven't found it...), and the fix the fuel gauge. It thinks it's empty at 1/2 tank.
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Old 04-17-2014, 11:17 AM
catamount catamount is offline
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Join Date: Feb 2012
Boat: 1987 ProStar 190
Location: Vermont
Posts: 359
Looks great! I have a very similar '87 PS190 that I did a similar refresh to (here).
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